Filter system

ABSTRACT

A vacuum cleaner having a reduced velocity chamber with a high velocity air inlet, an electric motor, a rotary mechanism driven by the motor for creating a vacuum in the chamber, an outlet for exhausting air from the chamber, which air flows in a selected path from the air inlet, through the chamber and out the air exhaust outlet and a disposable porous sheet filter layer in the chamber for removing large solid particles from the air. The vacuum cleaner also has an improved filter, wherein the improved filter includes a layer of material to remove very fine air particles and a layer of material to remove odors from the air.

This patent application is a continuation of application Ser. No.09,032,589 filed on Feb. 27, 1998, now U.S. Pat. No. 6,090,184, andincorporated herein by reference.

The present invention relates to the art of air filter systems and moreparticularly to an improved vacuum cleaner employing a novel filterelement. The invention is particularly applicable for a canister typevacuum cleaner and it will be described with particular referencethereto; however, the invention has much broader applications and may beused to filter air by employing the novel filter element and filteringmethod as contemplated by the present invention.

INCORPORATION BY REFERENCE

Frey U.S. Pat. No. 5,593,479 and Stevenson U.S. Pat. No. 5,248,323 areincorporated herein as background information regarding the type ofvacuum cleaner to which the present invention is particularlyapplicable. These two patents illustrate a canister type vacuum cleanerwith a low velocity receptacle or chamber into which is placed a conicalfilter sheet formed from non-woven cellulose fiber and over a downwardlyextending support structure for the purpose of removing particulatematerial from the air being processed through the vacuum cleaner. Therigid perforated conical support structure or member holds the filtersheet in its conical configuration. The support member and filter sheetare mounted together with the layer covering the rigid support member.Within the conical support member there is provided a generally flatdisc shaped cellulose filter sheet for further removal of particulatesolids as the solids pass with the air from the canister through theconical filter sheet and through the disc to the outlet or exhaust ofthe vacuum cleaner.

BACKGROUND OF INVENTION

A canister type vacuum cleaner is illustrated in the patentsincorporated by reference herein and includes a reduced velocity chamberwith a high velocity air inlet. Air is drawn into the chamber by anelectric motor which drives a rotary means, or fan, for creating vacuumin the chamber to draw air laden with particulate material through thechamber and to force it from the outlet as exhausted clean air. Canistertype vacuum cleaners normally include a conical filter extendingdownwardly into the canister or low velocity chamber and is formed of aporous mat to remove the dirt and debris carried by the air coming intothe canister. The high velocity air drawn into the chamber has atendency to entrain large solid particles which are brought into the lowvelocity chamber where the air is then swirled or vortexed in acentrifuge configuration with convolutions so that large particlescarried into the chamber with the inlet air are extracted by thevortexed or cyclonic action of the air in the canister. Thereafter, theair is pulled upwardly through the conical filter toward an upper motorthat drives a fan for creating a vacuum in the canister, or reducedvelocity chamber, so that the air flowing upwardly through the conicalfilter passes through a filter disc and outwardly through an exhaustpassage, or passages, above the canister. Stevenson U.S. Pat. No.5,248,323 discloses an improvement to filters for vacuum cleaners bydeveloping an activated charcoal containing filter which efficientlyremove gaseous impurities, such as paint fumes and other odor creatinggases which are in the air.

The canister type vacuum cleaner, as so far described, only removes therelatively large particles entrained in the air. Air particles of a sizeless than 10 microns pass freely through the filter medium and arerecirculated in the room. Many of these small particles can act asirritants to an individual and the recirculation of such particles canincrease the irritation to an individual. High density filters must beemployed to filter out very small particles in the air; however, highdensity filters cause large pressure drops through the filter and thuscannot be used in standard vacuum cleaners or other air filteringsystems. Frey U.S. Pat. No. 5,593,479 addressed this problem bydisclosing a multi layer filter which included at least one layer ofelectrically charged fiber material incapuslated between at least twolayers of support material. The multi-layer filter effectively removedvery small particles from the air which penetrated the cellulose fiberlayer. The patent also disclosed that a spongy non-woven polyester matimpregnated with activated charcoal could be used with the cellulosefilter and multi-layer filter to remove odors from the air.

Although the filter arrangement disclosed in Frey U.S. Pat. No.5,593,479 effectively removed fine particles from the air and could beadapted to also remove odors from the air, the use of three separatefilters proved confusing to many consumers. The three filter systemrequired the filters to be arranged in a certain order so as to maximizeparticle and odor removal efficiencies and to maximize the life of thethree filter system. The proper arrangement for the three filter systemwas confusing to many consumers and resulted in the improper arrangementof these filters. In addition to problems in arranging the order of thefilters, the three filters had to be correctly positioned with respectto one another so as to obtain the desired pressure drop through thethree filter system to obtain the desired particle remove efficiencies.The proper arrangement of the three filters proved to be, at times,tedious, complicated and/or confusing, thus resulting, at times, inreduced filter efficiencies and operating efficiencies. Finally, thethree filter system required the user to timely change each filter tomaintain the air filtering efficiencies and proper operation of thecleaning system. However, due to the use of three separate filters,confusion sometimes resulted as to when and/or which filter needed to bereplaced. As a result, one or more filters would not be timely replacedthereby resulting in subpar operation and filter efficiencies.

As a result, vacuum cleaners, in general, canister type vacuum cleaners,in specific, have not been designed to incorporate a simple filtersystem which can remove both odors and very small particles entrained inthe air.

SUMMARY OF THE INVENTION

The present invention relates to an improved air filtering system, andmore particularly to a vacuum cleaner with a novel filtering arrangementwhich allows a vacuum cleaner, and even more particularly to a canistertype vacuum cleaner, to be modified for the purpose of handling a widevariety of particles entrained in the air being drawn through the vacuumcleaner by an electric motor. In addition, the improved filtering systemis designed to remove odors from the air as the air passes through thefilter system. Thus, the filtering system can be an environmental aircleaning device as well as a standard vacuum cleaner.

In accordance with the present invention, there is provided animprovement in a vacuum cleaner of the type comprising a reducedvelocity chamber with a high velocity air inlet, an electric motor, arotary means driven by the motor to create a vacuum in the chamber, anoutlet for exhausting air from the chamber, which air flows in aselected path from the air inlet to the low velocity chamber and out theair exhaust outlet or outlets, and a disposable filter system in thechamber for removing solid particles from the air, which filter layerintersects the air path. The improvement in this type of vacuum cleaneris the provision of a changeable filter system which includes a filterwhich removes all sizes of particles including particles of less thanten microns in size. In this manner, the filter removes all sizes ofparticles entrained in the air to provide a significantly cleanerenvironment. Standard filter mediums filter out approximately 300,000particles out of 20 million particles which flow into the filter medium.Particles which are ten microns or less in size pass freely throughstandard filter medium. Such particles include pollen, dust mites,bacteria, viruses, etc. The recirculation of these small particles canspread diseases and/or cause allergic reactions. The improved filtersystem of the present invention includes a filter which removes allsizes of particles which result in about a 19 million particle removalout of 20 million particles which pass into the improved filter. As aresult, over 90% of the particles greater than 2 microns in size arefiltered out of the air passing through the improved filter. Theimproved filter is also designed to remove odors from the air which passthrough the filter. The improved filter includes an odor absorbingmaterial to remove odors from the air through the air filter.

In accordance with another aspect of the present invention, the improvedfilter includes two distinct sections. One section is designed to be ahigh efficiency particle removing section to remove very small particlesfrom the air passing through the filter. This section may use mechanicaland/or electrostatic capture mechanisms to remove particles entrained inthe air. This section may be comprised of one or more layers. The secondsection is designed to be a gas removal section to remove unwantedgasses from the air. This section may also be designed to removeparticles from the air. This second section may use mechanical and/orchemical capture mechanisms to remove gasses and particles from the air.This section may comprise one or more layers.

In accordance with yet another aspect of the present invention, the twosections of the improved filter are connected together. In one preferredarrangement, the two sections are connected together by an adhesive. Onesuch adhesive preferably used is a hot melt adhesive.

In accordance with still yet another feature of the present invention,the improved filter minimizes the degree of pressure drop as the airpasses through the filter. The relatively low pressure drop through theimproved filter enables the filter to be used in vacuum cleaners, suchas canister type vacuum cleaners or for various other types of airfilter systems.

In accordance with another feature of the present invention, theimproved filter both removes small particles and odors in the air as theair passes through the filter. This dual action filter eliminates theneed for a separate filter for small particle removal and a separatefilter for odor removal.

In accordance with yet another aspect of the present invention, the twosections of the improved filter are connected together so as to maintainthe integrity of the sections during operation and to minimize thedegree of pressure drop through the filter.

In accordance with still another aspect of the present invention, adisposable filter is used in conjunction with the improved filter toremove large particles entrained in the air prior to the air enteringthe improved filter. The use of a disposable filter for filtering largerparticles from the air enhances the life of the improved filter. Thedisposable filter can be a paper of cellulose type filter. Thedisposable filter is preferably generally coterminous to the improvedfilter.

In accordance with yet another aspect of the present invention, theimproved filter is conical in shape to maximize the surface area toprovide increased particle removal. In addition, the disposable filteris preferably conical in shape. Consequently, all the filters aresandwiched together thereby minimizing the area of filtration by thefilters and to ensure the filters are in the proper position in thevacuum cleaner. This construction allows the use of the filters to beeasily adapted for use in a standard canister type vacuum cleanerwithout modification of the vacuum cleaner.

In accordance with another aspect of the present invention, the improvedfilter includes a tab, loop or the like to facilitate the ease to whichthe filter can be positioned in the vacuum cleaner and/or removed fromthe vacuum cleaner. The tab, loop, etc. may also be used as an indicatorfor the proper position of the improved filter and/or includeinformation about the filter.

The primary object of the present invention is the provision of a novelfilter system that can effectively filter out a majority of theparticles entrained in the air and to remove odors in the air as the airpasses through the filter without causing a large pressure drop and canbe easily used in a vacuum cleaner such as a canister type vacuumcleaner.

Another object of the present invention is the provision of a filtersystem as described above, which filter system can be changed easily andcan be used in a standard canister type vacuum cleaner withoutmodification of existing vacuum cleaner structure.

Yet another object of the present invention is the provision of a filtersystem which reduces the number of filter components need to removeodors and particles from the air thereby reducing confusion as toassembly and maintenance of the filter system.

Still yet another object of the present invention is the provision of afilter system, as defined above, which filter system has a large area towhich the air flowing from the canister toward the exhaust outlet of thevacuum cleaner has a relatively large area compared to a standardcircular disc shaped filter element.

Yet another object of the present invention is the provision of aconical filter system adapted to be sandwiched within and held in anested position with a standard filter element of a canister type vacuumcleaner.

Still a further object of the present invention is the provision of afilter system, of the type defined above, which filter system is fixedlylocated in the reduced air velocity chamber or area of a vacuum cleanerso that low velocity air passes through the filter system to provideresident time to contact the large surface area of the filter system soas to remove particles from the air being cleaned by the vacuum cleaner.

In accordance with another objective of the present invention, theimproved filter and disposable filter are nested together and supportedby a support structure.

These and other objects and advantages will become apparent from thefollowing description taken together with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a pictorial exploded view of a standard canister type vacuumcleaner employing the improved filter system of the present invention;

FIG. 2 is a top view of a flat blank of the improved filter cut into ashape for subsequent forming into the preferred embodiment of thepresent invention;

FIG. 3 is a side view of the blank shown in FIG. 2 formed into a conicalfilter and showing the cross-section of the improved filter partially;

FIG. 4 is a side view of an alternative embodiment of the improvedfilter shown in FIG. 3;

FIG. 4A is a cross-section view of the improved filter along line 4A—4Aof FIG. 4;

FIG. 5 is a side elevational view showing the geometric configuration ofthe preferred embodiment of the present invention illustrated in FIGS. 2and 4;

FIG. 6 is a cross-sectional view of the improved filter along line 6—6of FIG. 4;

FIG. 7 is a schematic layout view of the air flow through a two filtersystem;

FIG. 8 is a schematic layout view of the air flow through an alternativeembodiment of a two filter system; and

FIG. 9 is a block diagram showing the filtering and operating steps of acanister type vacuum cleaner improved by incorporating the improvedfilter of the present invention.

DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring now to the drawings wherein the showings are for the purposeof illustrating a preferred embodiment of the invention only and not forthe purpose of limiting same, FIG. 1 shows a canister type vacuumcleaner A having a lower generally cylindrical canister 10 with a base12 and an upper circular opening defined by rim 14. In the illustratedembodiment, a plurality of circumferentially spaced wheels 16 supportcanister 10 for movement along the floor of a room being cleaned.Canister 10 includes a low velocity chamber 20 with a high velocityinlet 22, an air deflector 24 and a lower filter rest 26. Air flowthrough the vacuum cleaner is illustrated as arrows defining a path P.In chamber 20 of canister 10, path P is in the form of a vortexed orcyclone portion C of several convolutions so that particles carried byair through chamber 20 are removed by centrifugal force and are retainedin the low velocity chamber 20. Thereafter, air flow path P is generallyin an upwardly vertical direction so that the air being cleaned movesthrough a conical filter element, or layer, 30 formed from a flat,non-woven cellulose fiber with an outer conical surface 32 and an uppercircular opening 34. The diameter of open end 34 is X and the height ofa conical filter 30 is Y, as shown in FIG. 5. In this manner, asubstantially increased amount of filtering surface is obtained throughuse of a conical surface. Otherwise, filtering would be through acircular area defined by the diameter of open end 34. Filter layer 30 ispreferably designed to be relatively thin since it includes smallinterstices to physically block the passage of solid particles. Filterlayer 30 is a standard vacuum cleaner filter designed to act as abarrier to relatively large particles entrained in the air. Filter layer30 removes approximately 300,000 out of 20 million particles from theair as the air passes through filter 30. Very small particles passfreely through filter layer 30. Such filtration efficiency meetsstandard EPC guidelines.

To retain the conical shape of the relatively unstable conical element30, there is provided a filter support 40 having a large number ofperforations 42 and an upper circular rim 44. When assembled, conicalsupport 40 nests within the thin, conical filter layer 30 and rim 44clamps the filter layer against rim 14 of canister 10. The outer conicalsurface 46 bears against the inner conical surface of filter layer 30 innormal practice to support this conical filter element. As so fardescribed, air passes through the thin, non-woven conical cellulosefilter 30 through perforations 42 and upwardly in a direction defined byair path P.

In accordance with standard practice, a motor driven fan housing 50, ofthe type shown in the prior art, includes a lower inlet 52 and an airexhaust shown as a large number of peripherally spaced outlet exhaustopenings 54 having a common cylindrical secondary filter 56 for removalof any solid particles reaching housing 50. Secondary filter disc 60 isbefore motor 50 and is supported by a flat perforated support disc 62.As so far described, canister vacuum cleaner A is constructed inaccordance with standard practice.

In accordance with the invention, there is provided a novel filter 70for removing both small particles and odors from the air passing throughthe filter. As best shown is FIGS. 3, 4 and 6-8, filter 70 includes anodor removal section 76 and a particle removal section 78. The twosections are connected together by any number of arrangements, i.e.bonding agent, stitching, etc. Preferably a bonding agent 80 is used tosecure sections 76, 78 together. One such bonding agent which can beused is an adhesive, such as a hot melt adhesive. Preferably, thebonding agent is applied in a dot matrix pattern to secure sections 76,78 together so as not to cause a significant increase in pressure dropor a reduction in performance of filter 70.

Odor removal section 76 of filter 70 is designed to remove undesirablegases from the air such as smoke or other undesirable odors. The gasfilter section 76 comprises a mat of laid fibers. The fibers extend inall directions in the mat. The fibers are generally parallel to theforming surface on which the fibers are laid. The gas filter section 76may alternatively be a woven mat, a needled mat or a felted mat. The gasfilter section 76 preferably is made up of multiple layers of fibers.

The fibers are preferably cellulosic fibers and/or synthetic textilefibers. The fibers of the mat may be all cellulosic fibers or allsynthetic textile fibers or a mixture of cellulosic fibers and synthetictextile fibers. Alternately, one layer of the mat, or one layer may beall cellulosic fibers and another layer of the mat be all synthetictextile layer of the mat may be all cellulosic fibers and another layerof the mat be all synthetic textile fibers, with yet a further layer ofthe mat may be a mixture of synthetic textile fibers and cellulosicfibers. A wide variety of synthetic fibers may be used including acrylicfibers, polyester fibers, nylon fibers, olefin fibers, and vinyl fibers,and the like. The cellulosic fiber may be cellulose fibers, modifiedcellulose fibers, methylcellulose fibers, rayon and cotton fibers,although cellulose fibers are preferred.

Deposited on the fibers is a synthetic binder. The binder is designed toconnect the fibers together and can be chosen from a wide variety ofbinders including an acrylic latex, a vinyl latex, an acrylonitrilelatex, and an crylate latex. The binder substantially covers the surfacearea of the fibers, i.e. at least 50% of the fiber surface area, and isin an amount sufficient to bind the fibers together within the mat.

An absorbent powder, preferably in particle form, is disposed on thebinder. The absorbent powder may be a variety of powders such asactivated carbon, diatomaceous earth, fuller's earth and the like.Portions of the particles contact and are embedded into the binder, butportions of the particles protrude out of the binder and are free fromand do not substantially contact the binder. Those protruding portionsare, therefore, available to absorb odors as the air passes through thefilter layer.

As can be appreciated, odor removal section 76 is also designed toremove particles in the air that have passed through filter layer 30.The particle removal is by a mechanical and/or a chemical mechanism. Theclose spacing of the fibers making up section 76 mechanically removesparticles from the air by not allowing the particles to pass through thefilter section. The gas absorbing material in section 76 also can removematerials from the air by chemical attraction. Therefore, section 76 hasa dual mechanism for removing particles from the air.

The odor removal section 76 of filter 70 is preferably designed to beresistant to mold, mildew, fungus and bacteria. The odor removal section76 also is preferably designed to remove odors caused by AromaticSolvents, Polynuclear Aromatics, Halogenated Aromatics, Phenolics,Aliphatic Amines, Aromatic Amines, Ketons, Esters, Ethers, Alcohols,Fuels, Halogenated Solvents, Aliphatic Acids, Aromatic Acids, etc. Theodor removal section 76 may also be treated to resist damage fromliquids. Preferably, section 76 has a weight of 100-300 g/m² and morepreferably 150-225 g/m², and a gas absorbent content of 25%-80% and morepreferably 40%-60%.

The particle removal section 78 of filter 70 is designed to remove verysmall particles from the air. Preferably, section 78 is a highefficiency particulate air (HEPA) filter. Particle removal section 78 ispreferably a multi-layer arrangement which removes particlesmechanically and/or electrostatically from the air. Preferably theexterior surface layer of section 78 is made up of a relatively durablematerial so as to resist damage to the filter layer during operation ofthe air cleaner and/or during insertion on or removal of filter 70 fromthe air cleaner. The exterior surface is preferably a sheet ofpolyester, nylon or the like. The exterior surface may be woven ornon-woven. Section 78 is preferably formed of materials which resistgrowth to mold, mildew, fungus or bacteria. The materials alsopreferably resist degradation over time and are able to withstandextremes in temperatures and humidity, i.e. up to 70° C. (158° F.) and100% relative humidity. Therefore, the particle removal section 78 ispreferably unaffected by normal operating temperatures and water in theair. As a result, the filter 70 can be designed to be, if desired, usedin both wet and dry environments. Section 78 is designed to act as amechanical and/or electrical barrier to prevent air particles frompenetrating the fiber layer. Preferably, section 78 removes essentiallyall particles having a size greater than two microns. Particle removalsection 78 preferably has a 99% air filtration efficiency for particlesgreater than two microns in size. More preferably, section 78 filtersout over 99.9% of the particles 2 micron or greater in size, and evenmore preferably filters over 99% of the particles 0.3 micron or greaterin size. For particles from 0.3-2.0 microns, particle removal section 78has a filtration efficiency of at least 70% and more preferably at least99.9%. As a result, out of the millions of air particles entering thefiber layer, only a relatively few extremely small particles passthrough section 78 of filter 70. The weight of the material of section78 is 60-150 gm/m², and more preferably 62-90 gm/m², which results in avery nominal pressure drop as the air passes through section 78.

The multiple layers of section 78 are connected together by anyconventional means. Preferably, they are connected together by a binderand/or needle pointed together. The materials used to form section 78may be similar to the materials used in section 76.

The combining of odor removal section 76 and particle removal section 78complements each of the sections of filter 70 thereby resulting ingreater particle removal efficiencies. As illustrated in FIG. 7, filterlayer 30 mechanically removes the large particles 90 in air stream P.The smaller particles 92 freely pass through filter layer 30. Thesmaller particles 92 then encounter odor removal section 76 of filter70. Odor removal section removes odors such as smoke from the air byabsorbing such odors as the air passes through odor removal section 76.In addition, odor removal section 76 mechanically, and in someinstances, chemically removes smaller particles from air stream P byblocking their passageway and/or absorbing such particles. Odor removalsection 76 thus acts as a pre-filter of particles for particle removalsection 78. The remaining small particles 92 that pass through odorremoval section 76 are mechanically and/or electrically removed from airstream P by adhesive layer 80 and particle removal section 78. Particleremoval efficiencies as high as 99.98% for particles 0.1 micron andgreater in size and at air flow rates of 10-60 CFM are achievable byfilter 70. This filter arrangement has been found to also maximize thelife of the filter system.

An alternate embodiment of the invention is shown in FIG. 8. Thearrangement of the filter system is the same as shown in FIG. 7 exceptparticle removal section 78 is first exposed to small particles 92 aftersuch particles pass through filter layer 30. The particle removalefficiencies of this filter system arrangement are comparable to theparticle removal efficiencies of the filter system arrangementillustrated in FIG. 7. However, it has been found that the life offilter 70 is slightly shortened by this arrangement, but, in someinstances, the odor removal efficiencies are increased.

Referring now to FIG. 2, filter 70 is originally in a sheet form aftersections 76 and 78 are connected together. This sheet form is then cutout in a particular shape as shown in FIG. 2. The particular cut of thefilter material is then formed into a cone shaped filter as illustratedin FIGS. 3 and 4. This particular shape of filter 70 maximizes thesurface area of the filter for canister air cleaning systems utilizing avortex particle removal system. The ends of the filter material areattached together to form the conical shaped filter 70. Preferably, theends are connected together by a bonding agent 74, such as a hot meltadhesive. However, the ends of the filter can be connected together byother means such as stitches, staples, VELCRO, or the like.

Referring now to FIGS. 4 and 4A, an alternative embodiment of filter 70is illustrated. A tab 84 is connected to the top edge 72 of filter 70.Tab 84 is designed to facilitate in the ease of insertion and removal offilter 70 from filter support 40. Tab 84 may also include use,installation and/or replacement information to assist in the operationof the vacuum cleaner A. Tab 84 may also function as a positionalindicator to assist the user properly positioning filter 70 in vacuumcleaner A. Finally, tab 84 is preferably positioned on filter 70 tooverlap bonding agent 74 which connects the ends of filter 70 together.This positioning of tab 84 helps to protect and secure the seam formedby bonding agent 74. Tab 84 is preferably secured to both sides offilter 70 as shown in FIG. 4A. The tab is preferably secured to filter70 by a bonding agent such as a hot melt adhesive. However, tab 84 canbe connected to filter 70 by other means such as stitching, staples,etc. If desired, tab 84 can be designed to be easily removed by theuser.

The formed conical filter 70 preferably nests within conical filterlayer 30 and is sandwiched between filter layer 30 and filter support40. As illustrated in FIGS. 7 and 8, layer 30 acts as a mechanicalbarrier to prevent large particles 90 from entering into filter 70. Thesmall particles 92 which penetrate the small openings in layer 30 aresubsequently filtered out of the air by filter 70. The use of layer 30extends the life of filter 70 by filtering out the larger particleswhich can clog up the air passages in filter 70.

Referring now to FIGS. 1 and 9, it is shown that filter 30 and filter 70are sandwiched together so that air flowing through this filterarrangement is first intercepted by conical filter 30. This filterremoves the solid particles which have not been centrifuged out incanister 10. The air particles passing through filter 30 engage sections76 and 78 of filter 70. In addition, odors and other undesired gases aresimultaneously removed from the air as the air passes through section 76of filter 70. Thus, improved vacuum cleaner A can be used for cleaningfine particles from a room and can help sterilize a room from pollen,bacteria, viruses, microorganisms and the like, and also remove smokeand other unwanted gasses from the air. It is appreciated that thevacuum cleaner can clean the ambient air for a normal household use.

As shown in FIGS. 1 and 9, the air passes upwardly from the cycloneaction of canister 20 through exhaust 56 by passing filter 70 positionedbetween conical filter layer 30 and the flat filter disc, or secondaryfilter 60. FIG. 9 illustrates a novel method of processing air in avacuum cleaner, which novel method has not been heretofore available,especially in canister type vacuum cleaners. This novel method allowsthe vacuum cleaner to be capable of removing ultra fine particlesentrained within the air being cleaned, and also to simultaneouslyremove unwanted gasses from the air.

The dual functions of filter 70 greatly simplifies the operation ofvacuum cleaner A. Only two separate filters are required to be changedduring the operation of the vacuum cleaner A, i.e. filter 30 and filter70. The problems associated with the need for separate filters to obtainodorless clean air is solved by this filter system of the presentinvention. In addition, particle removal efficiencies never beforeobtained in portable vacuum cleaners are achieved by the filter systemof the present invention.

The invention has been described with reference to a preferredembodiment and alternatives thereof. It is believed that manymodifications and alterations to the embodiments disclosed will readilysuggest themselves to those skilled in the art upon reading andunderstanding the detailed description of the invention. It is intendedto include all such modifications and alterations insofar as they comewithin the scope of the present invention.

Having thus defined the invention, the following is claimed:
 1. Aparticle and gas removing filter substantially conical in shape forremoving odors and a majority of particles from air passing through thefilter, said filter comprising two separate filter sections and aconnector to connect together said two filter sections, said firstfilter section including fibers to mechanically remove particles fromsaid air and a gas absorbing material bonded to said fibers to at leastpartially remove at least one unwanted gas from the air, said secondfilter section including a particle barrier medium to mechanicallyand/or electrically remove at least about 99% of particles two micronsor larger in size from said air, said connector minimizing pressure dropof said passing air as said passing air passes from said first filtersection to said second filter section.
 2. A filter as defined in claim1, wherein said connector includes a bonding agent applied in a spaceddot matrix pattern.
 3. A filter as defined in claim 1, including a tabconnected to an edge of said filter.
 4. A filter as defined in claim 2,including a tab connected to an edge of said filter.
 5. A filter asdefined in claim 1, wherein said connector includes a bonding agentbeing a hot melt adhesive.
 6. A filter as defined in claim 4, whereinsaid bonding agent being a hot melt adhesive.
 7. A filter as defined inclaim 3, wherein said connector includes a bonding agent being a hotmelt adhesive.
 8. A filter as defined in claim 1, wherein first filtersection filters said passing air prior to said second section.
 9. Afilter as defined in claim 6, wherein first filter section filters saidpassing air prior to said second section.
 10. A filter as defined inclaim 1, wherein said second filter section including at least twolayers, said first layer being connected to said first filter section,said second layer being comprised of a durable abrasion and tearresistant material, said second layer including a material selected fromthe group consisting of polyester, cotton, nylon and combinationsthereof.
 11. A filter as defined in claim 9, wherein said second filtersection including at least two layers, said first layer being connectedto said first filter section, said second layer being comprised of adurable abrasion and tear resistant material, said second layerincluding a material selected from the group consisting of polyester,cotton, nylon and combinations thereof.
 12. A filter as defined in claim1, wherein said second filter section removing at least about 99.98% ofparticles 0.3 micron or greater in size from said passing air.
 13. Afilter as defined in claim 11, wherein said second filter sectionremoving at least about 99.98% of particles 0.3 micron or greater insize from said passing air.
 14. A filter as defined in claim 13, whereinat least about 99.98% of particles 0.1 micron or greater in size beingremoved from said passing air at flow rates of up to at least 60 CFM.15. A filter as defined in claim 1, wherein said filter is formed into asubstantially conical shape.
 16. In a vacuum cleaner or air cleanercomprising a reduced velocity chamber with a high velocity air inlet, amotor, a rotary blade driven by said motor to create a vacuum in saidchamber, an outlet to exhaust air from said chamber, said air flowing ina selected path from said air inlet, through said chamber and out saidair exhaust outlet, the improvement comprising a primary filterpositioned between said air inlet and said motor, said primary filterincluding first and second filter sections that are connected togetherby an attacher, said first filter section including a gas absorptionarrangement, said second filter section including a particle filterarrangement to remove over about 90% of said particles greater than 2microns in said air, said first filter section and said second filtersection are attached together by a securing arrangement, and saidsecuring arrangement minimizing pressure drop as said air passes fromsaid first filter section to said second filter section.
 17. The vacuumcleaner or air cleaner as defined in claim 16, wherein said securingarrangement includes a bonding agent applied in a spaced dot matrixpattern to said filter sections.
 18. The vacuum cleaner or air cleaneras defined in claim 17, wherein said bonding agent being a hot meltadhesive.
 19. The vacuum cleaner or air cleaner as defined in claim 16,wherein said second filter section includes at least two layers, saidfirst layer being connected to said first filter section, said secondlayer comprised of a durable abrasion and tear resistant material, saiddurable abrasion and tear resistant material including a materialselected from the group consisting of polyester, cotton, nylon andmixtures thereof.
 20. The vacuum cleaner or air cleaner as defined inclaim 16, wherein said first filter section includes non-woven fibersand a gas absorbing agent bonded to said fibers.
 21. The vacuum cleaneror air cleaner as defined in claim 16, wherein at least about 99.98% ofparticles 0.3 micron or greater in size are removed from said passingair.
 22. The vacuum cleaner or air cleaner as defined in claim 21,wherein at least about 99.98% of particles 0.1 micron or greater in sizeare removed from said passing air at flow rates of up to about 60 CFM.23. A particle and gas removing filter for removing odors and a majorityof particles from air passing through the filter, said filter comprisingtwo separate filter sections and a connector to connect together saidtwo filter sections, said first filter section including fibers tomechanically remove particles from said air and a gas absorbing materialbonded to said fibers to at least partially remove at least one unwantedgas from the air, said second filter section including a particlebarrier medium to mechanically and/or electrically remove at least about99% of particles two microns or larger in size from said air, saidconnector minimizing pressure drop of said passing air as said passingair passes from said first filter section to said second filter section.24. A filter as defined in claim 23, wherein said connector includes abonding agent applied in a spaced dot matrix pattern.
 25. A filter asdefined in claim 23, wherein said second filter section including atleast two layers, said first layer being connected to said first filtersection, said second layer being comprised of a durable abrasion andtear resistant material, said second layer including a material selectedfrom the group consisting of polyester, cotton, nylon and combinationsthereof.
 26. A filter as defined in claim 23, wherein said second filtersection including at least two layers, said first layer being connectedto said first filter section, said second layer being comprised of adurable abrasion and tear resistant material, said second layerincluding a material selected from the group consisting of polyester,cotton, nylon and combinations thereof.
 27. A filter as defined in claim23, wherein said second filter section removing at least about 99.98% ofparticles 0.3 micron or greater in size from said passing air.